Apparatus and method for density separator for drilling fluid

Abstract

An apparatus is disclosed for separating minerals in drilling fluid based primarily on density. The separator creates and maintains a slurry with a controllable density for separating minerals from drill cuttings. The density is controlled through the use of an electrode array. The separator comprises a primary separation chamber containing the dense slurry, and a multiple number of secondary separation chambers used to separate cuttings from the drilling fluid. The invention also contains inlet hardware allowing the mixed mineral suspension to enter the first separation chamber, and hardware allowing the three outlet (separated) streams to exit the device. One of the three outlet streams carries the minerals that have a density greater than the user selectable density set point, while the second carries the minerals that have a density less than the density set point, and the third carries clean drilling fluid.

What is claimed is: 
     
       1. A system for separating material from a fluid mixture, the system comprising:
 an inlet for the fluid mixture; and 
 a primary chamber coupled to the inlet for receiving fluid from the inlet, the primary chamber comprising:
 a first zone, wherein the first zone comprises an electrode array having at least two electromagnetic plates positioned one above the other to suspend a first material of the fluid mixture between the at least two electromagnetic plates; 
 a second zone situated above the first zone, wherein the second zone receives a second material of the fluid mixture that results above the first material; and 
 a third zone situated below the first zone to receive a third material that results below the first suspended material. 
 
 
     
     
       2. The system of  claim 1 , wherein the second zone comprises a lower launder and an upper launder, wherein the upper launder is positioned within the lower launder and wherein both the upper and lower launder each have a conduit extending outside the primary chamber. 
     
     
       3. The system of  claim 2 , wherein the electromagnetic plates comprise points and arcs that have opposite magnetic poles. 
     
     
       4. The system of  claim 2 , wherein the electrode array further comprises an electric coil positioned around the electromagnetic plates. 
     
     
       5. The system of  claim 2 , wherein the electrode array further comprises an electric coil positioned around the primary chamber. 
     
     
       6. The system of  claim 2 , wherein the system further comprises a level control mechanism to control a fluid level in the primary chamber. 
     
     
       7. A method for separating material from a fluid mixture, the method comprising the steps of:
 (a) supplying the fluid mixture; 
 (b) collecting the fluid mixture in a primary chamber, wherein the primary chamber comprises an electrode array having at least two electromagnetic plates positioned one on top of the other; and 
 (c) suspending a first material of the fluid mixture in the primary chamber between the at least two electromagnetic plates, wherein a second material of the fluid mixture results above the first suspended material and a third material of the fluid mixture results below the first suspended material. 
 
     
     
       8. The method of  claim 7 , wherein the electrode array comprises eight electromagnetic plates arranged into four upper and four lower plates and wherein the first material is suspended in the area between the four upper and the four lower plates.